Pre '96 Suzuki DR650S

[knybanjo]

Originally Posted by Trust

fits '91? (Says 96-08...)

Yeah...I'm pretty sure that the counter shaft splines are the same.

[BigHerm]

looking for mirrors. I need the right for sure but will buy a set. I assume the 96 and on will fit. Anyone need to clean out the garage????

[tdrrally]

i will tell my set go for $50.00 shipped

[BigHerm]

found what I need on CL in 5 min for 5.00. thanks for the offer though

[tdrrally]

drat there goes my bar end mirrors

congrats

[BigHerm]

pm braceface he has some to sell and he is too lazy to post them. Make him an offer

[Gibbonboy]

I've been working on my 90 for a while, wanted to paint it and had an issue where it would quit in wet weather. Thanks to some folks on here, I tried several different things and the problem is gone. I bought the bike in Sep 08, rode it all over and was pretty happy with it. I'll list what I did to it, then some pics.

New fork seals (I was being a puss about this, making a mountain out of a molehill, took me maybe 30 minutes once I actually did it)

New plug boots, seals, etc.

Repacked/rebuilt the muffler, and lowered the mounting by 1 1/2". The side panel and rear fender were badly burnt and melted by the leaking can and the tip rotating and pointing directly at the fender.

Added a piece of metal on the rear fender where it melted, cut out the slotted area in the side panel, filled the hole with some mesh, and put a better heat shield inside the panel.

Cut a Thermarest Trail seat into the seat foam, added about 1 1/4" of foam on the sides, and recovered it. I screwed up my first attempt, but I'll ride it for a while to see if I want to make changes before I cover it again.

Removed the side stand switch.

Still to do:
Fab new windscreen, 1-2" taller.
Paint my rubbermaid top box and remount.
Make/buy a waterproof mount for my radio.
Same for GPS.


And some pics- what it looked like before I really started, I had stripped some of the decals off, especially the tank.



And now:



Closer shot of the seat and side panel:




Anyway, been riding it for a few days and I'm really tickled. Thanks to all who contribute to this thread, keeping a 20-year-old thumper running is a full-time job (at least it seems like it). I expect the paint to chip and scratch, but touchups are cheap.

[Bnd1t02]

Hey guys,
Some of you are aware that I have been trying to sort out a motor mount
crack on my engine cases. The first question is wether the 90-91 inner engine cases are the same as the 92-95? The reason I ask this is cause 685 sent me the manuals and there was a seperate one for the 90-91's. I am still new to these bikes and are unaware of the differences.

My second question is if anyone has heard of torque related stress cracks on these motors? The very front motor mount hole under the oil return line
has a crack around the perimeter of the form on the case. There is no dents, scuffs, scratches or replaced parts leading me to beleive this bike has had any traumatic impacts anywhere near the motor. The welder that I had look at it said that he has seen some torque related cracks due to loosened motor mount bolts. Anyone here of this or experience this?

Jeremy

[tdrrally]

i have heard the crank on the e-start bikes is longer
the case should be the same less the e-start mounts
i would say any non e-start engine would be the same
this would include the sp600 as well

[BigHerm]

http://advrider.com/forums/showthread.php?t=601135

thought I wuold let you know

[685]

I've been traveling. . .not in sunny hott Tucson anymore for a while, but in overcast cool Western Washington, hoping at least until mid October. I'll be working driving a semi with double trailers to central WA and the Skagit valley (north of Seattle) to pick up fresh corn or carrots for a frozen food plant here in Chehalis.

I brought the DR for my transportation--easier to trailer than a car--so it's my sole trans for the rest of the summer and into the mid autumn. It's a great bike, but is in it's 20th summer, so pray for me that it answers the call each day it's needed. Should be interesting if it needs something, my only other trans is a 28 foot motor home.

While at my brother's (he had steel and a oxyacetelene torch) I fabricated some very simple and light duty saddle bag racks and mounted a box on the luggage carrier. Gotta be careful about weight, but for groceries and protective clothing it all should be effective. The side boxes are Pelican 1550 cases, btw. The box is one of those stocking boxes that they use to stock health and beauty aids in Grocery stores. With a top that actually closes (unlike a milk crate.)







The only project on tap this summer is to get a new tube in the rear tire--the current one requires daily air checks.

My DR got dangerously low on oil--I got overly distracted by other things. Check that oil, you guys!

[685]

Originally Posted by BigHerm

http://advrider.com/forums/showthread.php?t=601135

thought I wuold let you know

Nice bike--new tires? Good luck on finding it a new home.

[BigHerm]

Originally Posted by 685

Nice bike--new tires? Good luck on finding it a new home.

300 miles

[puntoMX]

Part II on the KLR650 shock:



I just did it with a handdrill, starting will a small 1mm drill, followed by a 4mm drill, 7mm drill,
and finally a 9.9mm drill, I got it 0.5mm on the left side so I had to do it the same on the
other side, most won't even see it.



This is how it looks now, I could have cut the lower parts off but it doesn't border me to
have those holes there.



This is how the bikes looks now, the highest point at the back is now 101cm and seat height
at the lowest point is 87cm. Shock is now set at 3 for pre-load and the max for rebound,
I don't know what the KLR guys are complaining about but when that shock is lubricated and
NOT under load, it's easy to set the pre-load to a higher level (Design fault my ).
I also lowered the front by 12mm and see how that goes. I'm pooped, it's 01:26 AM .

Will post back tomorrow... well, later today.

[nikolic]

Originally Posted by puntoMX

Part II on the KLR650 shock:



I just did it with a handdrill, starting will a small 1mm drill, followed by a 4mm drill, 7mm drill,
and finally a 9.9mm drill, I got it 0.5mm on the left side so I had to do it the same on the
other side, most won't even see it.



This is how it looks now, I could have cut the lower parts off but it doesn't border me to
have those holes there.



This is how the bikes looks now, the highest point at the back is now 101cm and seat height
at the lowest point is 87cm. Shock is now set at 3 for pre-load and the max for rebound,
I don't know what the KLR guys are complaining about but when that shock is lubricated and
NOT under load, it's easy to set the pre-load to a higher level (Design fault my ).
I also lowered the front by 12mm and see how that goes. I'm pooped, it's 01:26 AM .

Will post back tomorrow... well, later today.

I must admit I expected you will leave the seat hight over the 90! But anyway
nice job, for a good buck!